Photovoltaic Module Busbar Isolation for Jumper Wire Short-Circuit Prevention
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Solution Overview
Problem
The direct contact between jumper wires and interconnection strips in photovoltaic modules leads to electrical connections that adversely affect the normal operation of the module.
Innovation Solution
The implementation of intermediate busbars with lead-out terminals and isolation bars to prevent direct contact between jumper wires and solar cells, using L-shaped lead-out wires and diode junction boxes to manage current flow and reduce short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a jumper wire is used to electrically connect upper and lower solar cell string groups, then electrical connection is achieved, but direct contact between the jumper wire and solar cell array causes short circuits and operational inefficiencies
Solution Approach 1:
An isolation bar is introduced as an intermediary component between the jumper wire and the solar cell array. The isolation bar prevents direct contact between the conductive jumper wire and the solar cell array, thereby eliminating the short circuit risk while maintaining the electrical connection function through the lead-out terminals that extend beyond the isolation bar.
Solution Approach 2:
The lead-out terminals are designed to extend in a direction perpendicular to the plane of the solar cell array, moving the electrical connection point from the two-dimensional plane of the array to a three-dimensional space above it. This dimensional change allows the jumper wire to connect upper and lower string groups without contacting the solar cell array.
2Device complexity
If lead-out terminals are positioned close to the jumper wire for compact design, then device complexity is reduced, but the risk of electrical contact and short circuits increases
Solution Approach 1:
The isolation bar serves as a mediator that physically separates the lead-out terminals from the jumper wire path. Even though the lead-out terminals are positioned close to the jumper wire for compact design, the isolation bar ensures that they cannot make direct contact, thereby maintaining electrical isolation reliability while allowing compact positioning.
3Loss of energy
If the jumper wire is made more conductive to reduce serial resistance, then power loss is reduced, but the risk of harmful electrical effects and short circuits increases
Solution Approach 1:
The isolation bar acts as a mediator that allows the use of highly conductive jumper wire materials to reduce serial resistance and power loss, while simultaneously preventing the harmful electrical effects by blocking direct contact between the conductive jumper wire and the solar cell array.
Solution Approach 2:
The electrical connection system is segmented into distinct functional zones: the highly conductive jumper wire for current transmission, the isolation bar for electrical isolation, and the lead-out terminals for connection. This segmentation allows optimization of conductivity in the jumper wire without compromising safety.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Reduces serial resistance loss, increases power output by 3 levels, minimizes material consumption, and simplifies the manufacturing process while enhancing reliability and power generation efficiency.
Implementation Method 1
photovoltaic module includes: a first intermediate busbar having a first lead-out terminal provided at an end of the first intermediate busbar
Data Source
AI summary
Provided is a photovoltaic module, including a first intermediate busbar having a first lead-out terminal provided at an end thereof; a second intermediate busbar having a second lead-out terminal provided at an end thereof; and a first jumper wire arranged on a first isolation bar; the first lead-out terminal and the second lead-out terminal are located on two opposite sides of the first jumper wire, and the first lead-out terminal and the second lead-out terminal abut against two opposite side surfaces of the first isolation bar or overlap a top surface of the first isolation bar. Compared with the related art, the first isolation bar where the first jumper wire is located is clamped or pressed by the first lead-out terminal and the second lead-out terminal, to prevent short circuit or shielding of the cell caused by free movement of the first jumper wire, the first and second intermediate busbars.